U.S. patent application number 14/560304 was filed with the patent office on 2015-06-04 for lightweight animal litter.
The applicant listed for this patent is Normerica Inc.. Invention is credited to Kari Seguin-Laur.
Application Number | 20150150214 14/560304 |
Document ID | / |
Family ID | 52006876 |
Filed Date | 2015-06-04 |
United States Patent
Application |
20150150214 |
Kind Code |
A1 |
Seguin-Laur; Kari |
June 4, 2015 |
Lightweight Animal Litter
Abstract
A lightweight animal litter composition is provided that
comprises an absorbent clumping clay; a non-swelling ground
mineral; and an absorbent organic fiber which is preferably
recycled paper particles. The composition comprises a plurality of
particles, the components of the composition all being infused into
said particles.
Inventors: |
Seguin-Laur; Kari; (Dundas,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Normerica Inc. |
Port Credit |
|
CA |
|
|
Family ID: |
52006876 |
Appl. No.: |
14/560304 |
Filed: |
December 4, 2014 |
Current U.S.
Class: |
119/172 ;
264/140 |
Current CPC
Class: |
A01K 1/0154 20130101;
A01K 1/0155 20130101 |
International
Class: |
A01K 1/015 20060101
A01K001/015 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 4, 2013 |
CA |
2,835,579 |
Jan 28, 2014 |
CA |
2,840,686 |
Claims
1. A lightweight animal litter composition comprising: a recycled
absorbent clumping clay dust; and paper particles.
2. The lightweight animal litter composition according to claim 1
wherein the paper particles are recycled paper particles.
3. The lightweight animal litter composition according to claim 1
wherein the recycled paper particles are selected from the group
consisting of news grade 6, ONP (Old Newspaper) 7, ONP 8, ONP 9,
OCC and other recycled paper products.
4. The lightweight animal litter composition according to claim 1
wherein the absorbent clumping clay dust is selected from the group
consisting of sodium bentonite, calcium bentonite, Fuller's earth
and Montmorillonites.
5. The lightweight animal litter composition according to claim 1
further comprising a non-swelling ground mineral.
6. The lightweight animal litter composition according to claim 5
wherein the non-swelling ground mineral is selected from the group
consisting of coarse ground material, limestone, gravel, calcite,
soda ash and dolomite.
7. The lightweight animal litter composition according to claim 5
wherein the absorbent clumping clay dust is present in an amount of
20% to 80% by weight of the composition; the non-swelling ground
mineral is present in an amount of 5% to 72% by weight of the
composition; and the paper particles are present in an amount of 5%
to 50% by weight of the composition.
8. The lightweight animal litter composition according to claim 1
wherein the absorbent clumping clay dust is sodium bentonite dust
comprising particles that are sized such that less than 0.5% by
weight of the particles have US mesh size of smaller than 45,
preferably less than 0.5% by weight of the particles have a US mesh
size of smaller than 70.
9. The lightweight animal litter composition according to claim 1
wherein the paper comprises particles that are sized such that less
than 10% of the particles have a size of 2.00 mm, greater than 85%
of the particles have a US mesh size of 40, less than 5% of the
particles have a US mesh size of 50, and less than 2% of the
particles have a US mesh size of 70 wherein the pan is less than
1%, the density is 5-10 lbs/ft.sup.3 and the moisture is 4-15%.
10. The lightweight animal litter composition according to claim 1
wherein the composition is dust free.
11. The lightweight animal litter composition according to claim 1
wherein the composition comprises a plurality of particles, the
components of the composition all being infused into said
particles.
12. The lightweight animal litter composition according to claim 11
wherein the litter composition has a particle size of 98.5% between
4 US Mesh to a 100 US Mesh.
13. The lightweight animal litter composition according to claim 1
further comprising a bacterial enzyme for reduction of bacteria to
reduce odor.
14. The lightweight animal litter composition according to claim 1
further comprising a pH neutralizer.
15. The lightweight animal litter composition according to claim 14
wherein the pH neutralizer is baking soda.
16. The lightweight animal litter composition according to claim 1
further comprising a deodorizer.
17. A lightweight animal litter composition comprising: from 20% by
weight to 80% by weight of sodium bentonite dust; from of 5% to 25%
by weight of limestone; from of 20% to 80% by weight of recycled
paper particles; from of 0.1% to 10% by weight of bacterial enzyme;
from of 0.1% to 10% by weight of baking soda; and from of 0.001% to
10% by weight of scent.
18. A method for producing lightweight animal litter composition
comprising the following steps: providing sodium bentonite dust;
providing paper; providing an aqueous solution; preconditioning the
paper to form a paper formula; grinding the sodium bentonite dust
to a size of less than US Mesh 45 and premixing the sodium
bentonite dust with one of said additional components to form a
clay formula; blending the paper formula with the clay formula to
form a blend; mixing the blend with the aqueous solution to
agglomerate the composition into particles with sizes ranging from
4 to 50 US Mesh; and heat drying the composition.
19. A method according to claim 18 wherein the paper is recycled
paper.
20. A method according to claim 18 further comprising the step of
providing an additional component selected from the group
consisting of a pH neutralizer, a deodorizer, a bacterial enzyme
and a scent.
Description
FIELD OF THE INVENTION
[0001] An animal litter composition is presented that is
lightweight, includes recyclable materials and clumps upon
wetting.
BACKGROUND OF THE INVENTION
[0002] Animal litters are typically kept in litter boxes for the
purposes of collecting and disposing of urine and feces of domestic
animals. Materials as rudimentary as sand have been used as an
animal litter. Early versions of commercial animal litter included
clay. Clay litter is much more absorbent than sand, and its larger
grain makes it less likely to be tracked from the litter box.
Non-clumping animal litters are made of materials such as zeolite,
diatomite and sepiolite.
[0003] Clumping animal litter is the most used animal litter
product on the market. It has the advantage that the entire litter
box doesn't need to be emptied after use, as the wetted area
agglomerates and can easily be separated from the rest of the
litter. The majority of these types of litters utilize sodium
bentonite, a swelling clay known to absorb up to ten times its own
weight in water. Due to the diminishing availability of good
quality sodium bentonite, its cost has dramatically increased.
Therefore, in order to make this form of litter more cost effective
it is highly desirable to replace a significant portion of the
sodium bentonite with another lower cost material.
[0004] Minerals such as limestone are a good option as they are
readily available and abundant. However, these minerals are
non-swelling, and therefore can only replace a small amount of the
sodium bentonite in order for the litter to maintain its excellent
clumping properties. Another component is therefore required in
order to provide a lightweight and cost effective animal litter
composition that maintains excellent clumping strength.
[0005] There is therefore a need for a lightweight and cost
effective animal litter that has superior clumping properties.
SUMMARY OF THE INVENTION
[0006] An animal litter composition is provided that includes an
absorbent clumping clay which is preferably an absorbent clumping
clay dust that is preferably recycled dust from the cat litter
industry and an absorbent organic fiber in the form of wood fibers,
wood particles, saw dust, whole grains, legumes, nuts and
gymnosperm seeds and/or paper particles, preferably recycled
particles.
[0007] According to one aspect of the invention, there is provided
a lightweight animal litter composition comprising a recycled
absorbent clumping clay dust; and paper particles which are
preferably recycled paper particles.
[0008] According to another aspect of the invention, there is
provided a lightweight animal litter composition comprising the
following components: an absorbent clumping clay dust; preferably a
non-swelling ground mineral; and an absorbent organic fiber,
wherein the composition comprises a plurality of particles, the
components of the composition all being infused into said
particles.
[0009] According to another aspect of the invention, there is
provided a lightweight animal litter composition comprising: from
20% by weight to 80% by weight of sodium bentonite dust; preferably
from of 5% to 25% by weight of minerals; from of 20% to 80% by
weight of an absorbent organic fiber which is preferably recycled
paper; from of 0.1% to 10% by weight of bacterial enzyme; from of
0.1% to 0% by weight of baking soda; and from of 0.001% to 10% by
weight of scent.
[0010] According to another aspect of the present invention there
is provided a lightweight animal litter composition comprising from
20% by weight to 80% by weight of sodium bentonite dust; from of 5%
to 25% by weight of limestone; from of 20% to 80% by weight of
recycled paper particles; from of 0.1% to 10% by weight of
bacterial enzyme; from of 0.1% to 10% by weight of baking soda; and
from of 0.001% to 10% by weight of scent.
[0011] According to another aspect of the invention, there is
provided a dust free, ammonia neutralizing, antibacterial animal
litter preferably formed largely from recyclable materials that
clumps upon wetting. This animal litter is formed to a particular
size from pre-conditioned recycled paper and clay. The process of
making the litter particles allows the ingredients of the particles
to be infused to enhance its ammonia neutralizing and antibacterial
capabilities by evenly dispersing the ingredients within the matrix
of the particles versus traditional spray application of
ingredients onto clay/litter granules.
[0012] According to another aspect of the invention, there is
provided a lightweight animal litter composition comprising: a
recycled absorbent clumping clay dust; and an organic absorbent
fiber selected from the group consisting of wood fibers, wood
particles, saw dust, whole grains, legumes, nuts, gymnosperm seeds,
paper particles, and combinations thereof.
[0013] According to another aspect of the invention, there is
provided a method for producing a lightweight animal litter
composition comprising the following steps: providing sodium
bentonite dust;
providing recycled paper; providing an aqueous solution; providing
an additional component selected from the group consisting of a pH
neutralizer, a deodorizer, a bacterial enzyme and a scent;
preconditioning the recycled paper to form a paper formula;
collecting and grinding the sodium bentonite dust to a size of US
Mesh 45 to US Mesh 325, preferably less than US Mesh 70; premixing
the sodium bentonite dust with one of said additional components to
form a clay formula; blending the paper formula with the clay
formula to form a blend; mixing the blend with the aqueous solution
to agglomerate the composition into particles with sizes ranging
from 4 to 50 US Mesh; and heat drying the composition.
IN THE DRAWINGS
[0014] FIG. 1 is a flow chart showing a preferred process for
making an embodiment of the animal litter of the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] The present invention is a lightweight animal litter
composition that forms clumps upon wetting from waste material by
the animal. The animal litter composition comprises an absorbent
clumping clay dust or powder, preferably a non-swelling ground
mineral and an absorbent organic fiber which is preferably recycled
paper particles and most preferably ONP (Old Newspaper) grade 6, 7,
8, and/or 9. The absorbent organic fiber can also include
non-recycled paper particles. Preferably, the composition includes
an antimicrobial, pH neutralizer and a deodorizer. The components
of the composition are homogeneously infused into individual
particles of the composition. The wetted animal litter composition
agglomerates into a large and stable mass permitting physical
separation and removal of the wetted mass of particles from
unwetted particles of the composition. Removing the wetted
agglomerated composition particles from the remaining unwetted
composition reduces or eliminates offensive odors produced by dross
soaked particles.
[0016] The composition is lightweight and is preferably dust free.
The animal litter of the present invention is formed to a
particular size from pre-conditioned recycled paper and clay as
discussed in more detail below.
[0017] The process of making the litter particles allows the
ingredients of the composition to be infused into the particles
that constitute the composition, to enhance its ammonia
neutralizing and antibacterial capabilities by evenly dispersing
the ingredients within the matrix of the particles versus
traditional spray application of ingredients onto the surface of
the clay/litter granules.
[0018] The composition is preferably dust free. Dust free means
less than about 1% fines are smaller than 100 US Mesh. Also, less
than about 1% of clay weight is lost when pouring. In addition, it
takes less than 10 seconds for visual airborne dust to dissipate
after 2 kg of litter has been poured.
[0019] The composition includes an absorbent clumping clay which is
preferably absorbent clumping clay dust. This can also be referred
to as a particulate swelling clay. The absorbent clumping clay is
preferably sodium bentonite. Sodium bentonite is provided in the
form of sodium bentonite dust. The sodium bentonite dust is
preferably obtained from recycled animal litter or other recycled
material. As absorbent clumping clay is processed and packaged, it
generates airborne dust. The airborne clay dust is then vacuumed
away through a series of hoses integrated throughout a processing
line. The clay dust is separated out of the air by using a large
filter. The clumping clay dust in the air goes to the large filter.
The captured dust in the filter is released from the filter into a
collection area and is ready for removal and/or recycling. Other
clays that form clumps when contacted with water may be used as an
absorbent clumping clay for the purposes of the present
invention.
[0020] The absorbent clumping clay is present in the composition in
an amount of about 20% by weight to about 80% by weight of the
composition. The preferred content of the absorbent clumping clay
is about 45% by weight of the composition.
[0021] The lightweight animal litter composition of the present
invention preferably includes a non-swelling ground mineral. The
preferred non-swelling ground mineral is limestone. Dolomite can
also be used as the non-swelling ground mineral for the purposes of
the present invention. Other acceptable non-swelling ground
minerals for the purposes of the present invention include carbon,
graphite, soda ash and gravel.
[0022] The non-swelling ground mineral is preferably present in the
composition in an amount of about 5% by weight to about 25% by
weight of the composition. The preferred content of the
non-swelling ground mineral is about 10% by weight of the
composition.
[0023] The lightweight animal litter composition of the present
invention further includes absorbent organic fibers preferably in
the form of paper particles which are more preferably recycled
paper particles. The recycled paper particles are preferably grade
6 newspapers for recycling, #7ONP (Old Newspaper), #8 ONP, grade 9
(OI or OIN).
[0024] Grade 7 (#7 ONP) is de-ink quality news materials for paper
recycling are made up of fresh and sorted newspapers that aren't
damaged by the sun and don't contain more than the normal
percentage of colored sections and rotogravure.
[0025] Grade 8 (#8 ONP) is de-ink quality special news materials
for paper recycling that consists of fresh sorted newspapers that
are free from sun damage. This grade shouldn't include anything
other than news materials such as magazines, and is tare-free. It
also shouldn't contain more than the normal percentage of colored
sections and rotogravure.
[0026] Grade 9 (OI or OIN) is over-issue news for paper recycling
is comprised of unused, overrun newspaper that's bundled and
doesn't contain more than the normal percentage of colored sections
and rotogravure.
[0027] Other standard recycled paper grades can be used for the
purposes of the present invention. Table 1 sets out a summary of
the preferred recycled paper grades.
TABLE-US-00001 TABLE 1 Preferred Recycled Paper grades Paper Grade
Description News: Grade 6 Newspapers for recycling. News, De-Ink
Quality: Grade 7 (#7 De-ink quality news materials for ONP) paper
recycling are made up of fresh and sorted newspapers that aren't
damaged by the sun and don't contain more than the normal
percentage of colored sections and rotogravure. Special News,
De-Ink Quality: De-ink quality special news for Grade 8 (#8 ONP)
paper recycling consists of fresh sorted newspapers that are free
from sun damage. This grade shouldn't include anything other than
news such as magazines, and is tare-free. It also shouldn't contain
more than the normal percentage of colored sections and
rotogravure. Over-Issue News: Grade 9 (OI or Over-issue news for
paper recycling OIN) is comprised of unused, overrun newspaper
that's bundled and doesn't contain more than the normal percentage
of colored sections and rotogravure.
[0028] Other grades of recycled paper can be used for the purposes
of the present invention such as corrugated containers: Grade 11
(OCC) and Double Sorted Corrugated: Grade 12 (DS OCC).
[0029] The absorbent organic fibers may comprise wood fibers, wood
particles, saw dust or combinations thereof. The wood fibers, wood
particles, and saw dust can be derived from any type of wood.
[0030] In addition, the absorbent organic fibers can include fibers
from whole grains, legumes, nuts and gymnosperm seeds.
[0031] Examples of acceptable whole grains include: amaranth,
barley, brown rice, buckwheat, bulgur, farro, flaxseed, grano,
fonio, palmer's grass, wheat, millet, oat, corn/maize, muesli,
quinoa, rye, sorghum, spelt, teff, triticale, wild rice, sesame,
pitseed goosefoot, kaniwa, chia and breadnut.
[0032] Examples of acceptable legumes include: lentils, beans,
bambara groundnut, chickpea, cowpeas, blackeye peas, fava or broad
bean, hyacinth bean, lupin, moringa, peas, peanuts, pigeon peas,
sterculia peas, velvet peas, winged peas, yam beans, and
soybeans.
[0033] Examples of acceptable nuts include: acorn, amond, beech,
brazil nut, candlenut, cashews, chestnuts (Chinese and sweet),
chilean hazel, coconut, egusi and other melon seeds, colocynth,
malabar gourd, pepita, ugu, hazelnuts_filbert, hickory_pecan, kola
nut, macadamia nut, malabar nut, malabar chestnut, mamoncillo,
mongongo, ogbono, paradise nut, pili, pistachio, walnut--black
walnut, water chestnut, and shagbark hickory.
[0034] Examples of acceptable gymnosperm seeds include: cycads,
ginkgo, gnetum, juniper, monkey-puzzle, pine nuts, chilgoza pine,
Korean pine, Mexican pinyon, pinon pine, singel-leafpinyon, stone
pine, and pxlocarps.
[0035] Other acceptable whole grains, legumes, nuts and gymnosperm
seeds include: cempedak, cocoa bean, coffee bean, fox nut, hemp,
jackfruit, lotus seed and sunflower.
[0036] The absorbent organic fibers are present in the composition
in an amount of about 20% by weight to about 80% by weight of the
composition. The preferred content of the absorbent organic fibers
is about 45% by weight of the composition.
[0037] The absorbent clumping clay, preferably the non-swelling
ground mineral and the absorbent organic fibers are formed together
in particles in the animal litter composition. A preferred
embodiment of the animal litter composition includes sodium
bentonite dust, non-swelling ground minerals and paper particles.
Table 2 sets out the preferred physical properties of the particles
including ideal size distribution, density and moisture levels.
TABLE-US-00002 TABLE 2 Physical Properties +10 +40 +50 +70 -70/Pan
USMesh USMesh USMesh USMesh USMesh Density 2.00 mm 425 .mu.m 300
.mu.m 212 .mu.m 212 .mu.m (lbs/ Moisture Ingredient 0.0787''
0.0165'' 0.0117'' 0.0033'' 0.0033'' ft.sup.3) (%) Sodium 0.0% 0.0%
0.0% <0.5% 100% 60-64 8-14% Bentonite dust Non- 0.0% 0.0% 0.0%
<0.5% 100% 60-75 8-14% Swelling Ground Minerals Paper <10.0%
>85.0% <5.0% <2.0% <1.0% 5-10 4-18% Particles
[0038] The composition preferably includes a bacterial enzyme that
lyses the cell membranes of bacteria thereby destroying bacteria
that can be present in the litter after it has been used. This has
the result of reducing the amount of bacteria in the composition
and the resultant odor caused thereby. The bacterial enzyme is
preferably present in an amount of about 0.1% by weight to about
10% by weight of the composition. The preferred content of the
bacterial enzyme is about 0.5% by weight of the composition.
[0039] The composition preferably includes a pH neutralizer that
acts as a buffer to maintain the pH of the composition that avoids
the formation of ammonia from urine which forms at higher pH levels
producing unpleasant smells. The preferred pH neutralizer is baking
soda. However, a person skilled in the art will appreciate that
other pH neutralizers can be used. The pH neutralizer is preferably
present in an amount of about 0.1% by weight to about 10% by weight
of the composition. The preferred content of the pH neutralizer is
about 0.5% by weight of the composition.
[0040] The composition further preferably includes a deodorizer.
The deodorizer can be cedar scent for example or essential oils.
Preferred deodorizers include cedar, pine and other fragrances. The
deodorizer is preferably present in an amount of about 0.001% by
weight to about 10% by weight of the composition. The preferred
content of the deodorizer is about 0.05% by weight of the
composition.
[0041] As a result of infusing the components of the composition
into the particles of the formulation, a homogenous mixture of the
components is provided in each particle of the composition
throughout the composition.
[0042] A preferred animal litter formulation of the present
invention is set out in Table 3:
TABLE-US-00003 TABLE 3 Ingredient Inclusion (% w/w) Clumping
Clay/Sodium 44.62% Bentonite Minerals/Limestone 10.00% Recycled
Paper/Ground Paper 44.61.00% Antibacterial/Bacterial Enzyme 0.20%
pH Neutralizer/Baking Soda 0.50% Deodorizer/Scent 0.07%
[0043] The components of the animal litter formulation are infused
into individual particles. After blending, the composition is
preferably a granular mix of particles. The finished product is
dark grey in color with zero airborne dust, a bulk density of 30-45
lbs/ft.sup.3 which is half of the bulk density of standard clumping
litter. The composition preferably includes sodium bentonite dust,
preferably ground minerals, odor control, pH neutralizing and
deodorizing capabilities.
[0044] In processing the components of the animal litter
formulation, recycled paper products are pre-conditioned before
blending by shredding the paper product first followed by grinding
the paper product to 0.5 mm particle size. Similarly, the absorbent
clumping clay dust, ground minerals, pH neutralizer, and dry
deodorizer formula are ground to a size of less than US Mesh 70 and
premixed prior to blending with the pre-conditioned paper product
formula. The recycled paper and clay dust formula are then blended
together and finally mixed with the aqueous formulation of water,
liquid pH neutralizer, liquid scent and antimicrobial agent. All
three components come together into a pin mixer where the
components are agglomerated into particles with sizes ranging from
8 to 50 US Mesh. The particles are then heat dried preferably using
a gas fired, indirect heat drum dryer until they reach the ideal
moisture content of 4-18%. However, other dryers can be used for
the drying step.
[0045] A preferred method for producing an embodiment of the animal
litter of the present invention is depicted in the flow chart shown
in FIG. 1. The three components are recycled paper (ONP), recycled
sodium bentonite (clay) dust and an aqueous solution made of water,
antibacterial, and liquid deodorizer.
[0046] As a first step, bales of recycled paper ONP are provided
10. The bales of recycled paper are received and de-baled. The
recycled paper may then be pre-conditioned by shredding to
approximately 1-2 cm in width as indicated at 12. The next step 14
involves grinding the re-cycled paper to a grind size of less than
0.5 mm. Alternatively the step indicated at 14 may directly follow
the step indicated at 10 of providing bales of recycled paper ONP.
The step indicated at 34 is loading the pre-conditioned or ground
recycled paper into a hopper. Step 34 yields the paper component of
the animal litter.
[0047] Concurrently, recycled sodium bentonite dust/mineral is
provided 16 having <70 US Mesh. A following step 18 involves the
formulating the sodium bentonite (clay) dust with minerals, pH
neutralizer, and dry deodorizer to provide a sodium bentonite
(clay) dust formulation.
[0048] As shown at 38 the sodium bentonite dry formula is loaded in
a hopper to provide the clay component of the animal litter.
[0049] The next step 20 is the mixing of the paper component and
the clay component of the animal litter formulation to form a
blend. This is preferably carried out in an auger blender to
homogeneously mix the paper and clay components thereby forming a
paper and clay mixture. Other mixing methods known in the art may
also be employed for this step.
[0050] Step 22 provides an aqueous solution made of water at
5-35.degree. C., antibacterial, and liquid deodorizer and adding
the aqueous solution to the recycled paper and clay dust mixture at
approximately 10% of total stored in a tank. The clay dust and
recycled paper form 0.90% of total stored in a tank and the aqueous
solution forms 10%. All are added to the pin mixer. Following step
22, in step 24 the components including the blend and the aqueous
solution are then added to a pin mixer for pin mixing of the paper
and clay mixture for forming into particle sizes of >95% between
4 and 50 US Mesh. Step 24 is preferably carried out at 1-25.degree.
C.
[0051] Step 26 follows which involves drying the formed particles
to a moisture content of <14.0%. The drying step is preferably
carried out in a drum dryer. Once the paper/clay animal litter
particles are formed into small spherical granules from the pin
mixer, they are then continuously fed into the drum dryer where
they can gently roll in the cylinder for a specific period of time.
This time depends on load size. The angle of the barrel can be
adjusted to ensure that the amount going in is the same as the
amount going out.
EXAMPLES
Example 1
Standard Sodium Bentonite Litter Vs Lightweight Agglomerated Animal
Litter of the Present Invention
Objectives:
[0052] To compare agglomerated animal litter of the present
invention at four different formulations to standard clumping
sodium bentonite litter for appearance and functionality.
Materials:
[0053] 1. Standard Sodium Bentonite Litter [0054] 2. Agglomeration
Formula 1 . . . 25% Highly ground ONP #8: 75% Sodium Bentonite dust
[0055] 3. Agglomeration Formula 2 . . . 50% Highly ground ONP #8:
50% Sodium Bentonite dust [0056] 4. Agglomeration Formula 3 . . .
25% Highly ground OCC #11: 75% Sodium Bentonite dust [0057] 5.
Agglomeration Formula 4 . . . 50% Highly ground OCC #11: 50% Sodium
Bentonite dust Sufficient water for processing
Procedures:
1 Sieve Testing
1.0 Scope
[0058] This procedure is applicable to all finished product or raw
material, 10/40 and 12/40 mesh sized, sodium bentonite. The Sieve
Analysis of the sodium bentonite is to ensure that the sodium
bentonite types meets the standards.
2.0 Equipment
[0059] 2.1 Mesh Sizes--#10 or 12, 40, 50, 70, sieve pan and
lid--sequence for 10/40 and 12/40 raw material sodium bentonite
respectively. 2.2 Mesh Sizes--#40, 50, 70, sieve pan and
lid_sequence for finished product sodium bentonite
2.3 Sieve Shaker
[0060] 2.4 Steel bowl 2.5 PG5002-S scale, Balance (accurate to 0.01
g)
3.0 Procedure
[0061] 3.1 Stack from top to bottom: the sieve lid, #10 mesh or #12
mesh, (depending on the 10 or 12 sized clay respectively), followed
by #40 mesh, #50 mesh, #70 mesh and the pan. 3.2 Weigh out 500 g of
sodium bentonite in a tarred lab sample tray. 3.3 Remove the sieve
lid from the stack of sieves and transfer the 500 g of sodium
bentonite to the #10 Mesh sieve. 3.4 Replace the sieve lid back
onto the stack of sieves. 3.5 Place the stack of sieves onto the
seat of the shaker units. 3.6 Secure the stack onto the sieve
shaker. 3.7 Turn the timer to 10 minutes. 3.8 Once machine has
completed the 10-minute cycle, remove the stack. 3.9 Remove each
sieve and weigh the contents. 3.10 Calculate the % Weight of each
sieve content as follows:
Step 1
[0062] Total Sample Weight is calculated by adding each of the
Individual Sieve Weights together.
Sample Calculation
Individual Sieve Weight
#40 Mesh=497.06 g, #50 Mesh=2.13 g, #70 Mesh=0.16 g, Pan=0.65 g
[0063] Total Sample Weight=497.06 g+2.13 g+0.16 g+0.65 g=500.54
g
Step 2
[0064] Each Individual Sieve Weight by Percent is calculated by
taking each Individual Sieve Weight, dividing it by the Total
Sample Weight and multiplying it by 100.
Sample Calculation
[0065] Individual Sieve Weight by Percent = Sieve Weight Total
Sample Weight .times. 100 % = 497.06 g 500.54 g = 99.3 %
##EQU00001##
3.11 Repeat steps 2 for each Individual Sieve Weight to calculate
each Individual Sieve Weight by Percent.
4.0 Record
[0066] 4.1 Record the results
5.0 Specification
TABLE-US-00004 [0067] 5.1 +# 10 Mesh 20.0% Maximum 5.2 +# 40 Mesh
98.5% +/- 2.0% 5.3 -# 40/+# 50 Mesh 1.5% +/- 0.5% 5.4 -# 50/+# 70
Mesh 1.5% +/- 0.5% 5.5 -# 70 Mesh/Pan 0.5% +/- 0.5%
2. Percent Moisture
1.0 Scope
[0068] This procedure is applicable to all finished product or raw
material, 10/40 and 12/40 mesh sized, sodium bentonite. Percent
Moisture analysis provides information on the clay's ability to
absorb.
2.0 Equipment
2.1 Satorius Moisture Analyzer MA 30
3.0 Procedure
[0069] 3.1 Turn on unit by pressing On/Tare. 3.2 Parameters should
be set for 130.degree. C. and Auto time. See below as to how to
change parameters. 3.3 Lift hood and position disposable aluminum
tray on the internal scale 3.4 Press enter and the display will
zero and beep at the same time. 3.5 Weigh out 10 g of sample onto
the tray, making sure the product is distributed evenly on the
tray. 3.6 Close the lid of the Satorius Moisture balance to start
the test.
3.7 Changing Parameters:
[0070] 3.8 To change parameter Press CF the display shows, press F1
for a higher temperature and F2 for lower temperature. Press enter
to accept this temperature. 3.9 To change shutoff time press F1 to
increase or F2 to decrease the time. 0.0 min:auto indicates the
time will shut off when the temperature of the product does not
change. 3.10 Press enter to accept this time.
4.0 Record
[0071] 4.2 Record the results;
5.0 Specification
5.1 Sodium Bentonite <12.0% Maximum
3. Absorption
[0072] Absorption is measured by methods known in the art.
4. Density
1.0 Scope
[0073] This procedure is applicable to all finished product or raw
material, 10/40 and 12/40 mesh sized, sodium bentonite. Density
analysis provides information on the fill capability of the
product. By monitoring density rates, one can ensure proper fill
and reduce overfill spillage in the containers.
2.0 Equipment
[0074] 2.1 Seedburo Filling Hopper and stand.
2.2 Pint Cup
[0075] 2.3 Strike-off stick 2.4 PG5002-S scale, Balance (accurate
to 0.01 g)
3.0 Procedure
[0076] 3.1 Pour the sample of Clay into the Seedburo filling
Hopper. 3.2 Weigh the empty Pint Container. 3.3 Open slide gate at
bottom of the Hopper. Let the clay overfill the one-pint dry
measure container. 3.4 Make two passes with the Strike_Off stick at
the top of the one-pint dry measure container, to remove all
overfilled material. 3.5 Weigh the sample on the balance. 3.6
Calculate the weight of the sample by following the calculation
below.
Density=Sample Weight.times.0.1130 lb/ft.sup.3
4.0 Record
[0077] 4.3 Record the results
5.0 Specification
[0078] 5.1 Sodium Bentonite--70 lb/ft.sup.3+/-10 lb/ft.sup.3
5. Airborne Dust
1.0 Scope
[0079] This procedure is applicable to all finished product or raw
material, 10/40 and 12/40 mesh sized, sodium bentonite. The
Airborne Dust Analysis of the sodium bentonite provides information
on the dust content and must confirm the sodium bentonite meets
standards as well as monitors the dust collection system for the
Clay Handling System.
2.0 Equipment
[0080] 2.1 Plastic container . . . . 250 ml size.
2.2 Tray
3.0 Procedure
[0081] 3.1 Take a 250 g sample of clay. 3.2 Continuously pour the
250 g sample of clay from a height of 14''into a second container
(this should take approximately 3 seconds to pour 250 g sample of
clay). 3.3 Measure the time it takes for the dust generated from
pouring to dissipate; measure time in seconds.
4.0 Record
[0082] 5.1 Record the results.
6.0 Specification
[0083] 5.1 Bentonite--10 seconds Maximum.
6. Odour Control
1.0 Scope
[0084] This procedure is applicable to all finished product or raw
material, 10/40 and 12/40 mesh sized, sodium bentonite. The Odor
Control Analysis of the sodium bentonite provides information on
the clay's ability to remove odor over a defined period of
time.
2.0 Equipment
[0085] 2.1 250 ml container with lid 2.2 Self Zeroing 50 ml burette
2.3 10% Ammonia solution 2.4 Wax pencil
3.0 Procedure
[0086] 3.1 Take a 200 g sample of Sodium Bentonite and place it in
a 250 ml container with a lid. 3.2 Using the burette with the
dispensing end 2 inches from the surface of the sodium bentonite
sample, gently dispense 15 ml of the 10% Ammonia solution. 3.3
After dispensing the ammonia solution, assess the odor immediately
by sniffing the surface of the sample without disrupting it. 3.4
Record the results on the appropriate QA form. 3.5 The odor is
graded on a 10-point scale, 1_strong ammonia odor and 10_no ammonia
odor. 3.6 Assess the odor and grade at 24 and 48 hours. 3.7 Record
the results on the appropriate QA form.
4.0 Record
[0087] 5.2 Record the results
7.0 Specification
[0088] 5.1 Sodium Bentonite 0 hour--5, 24 hour.sub.--7, 48
hour--9
Results and Discussion:
TABLE-US-00005 [0089] Standard Sodium Agglomeration Bentonite
Formula 1 Formula 2 Formula 3 Formula 4 Analysis Litter 250NP:75SB
500NP:50SB 250CC:75SB 500CC:50SB Colour Blue/Grey Grey Grey Grey
Grey Scent Unscented Unscented Unscented Unscented Unscented
Particle US +10 20.0 40.0 26.0 Size/ US +40 98.5 Sieve US -40/+50
1.5 Analysis US -50/+70 0.5 -70/PAN 0.2 0.1 0 0.1 0.1 Moisture (%)
<12.0% <12.0 <12.0 <12.0 <12.0 Clump Weight 40.0
52.5 33.0 46.5 37.0 Clump Weight 51.5 32.0 46.0 35.5 Clump Strength
98.1 97.0 98.9 95.9 Bulk Density 63.0 57.3 43.1 60.1 49.7 Airborne
Dust 5-7 0-1 0-1 0-1 0-1 Odour 0-1 Hour 5-9 Good Good Accept Poor
Control 24 Hour 7-10 Good Good Accept Poor 48 Hour 9-10 Good Good
Poor Poor .sup.1Before Drop Test .sup.2After Drop Test .sup.30dour
Control: 1 = poor odour control, 10 = excellent odour control
Conclusions
1. Colour
[0090] Formula 1 and 2 (ONP) are acceptable grey colour whereas
Formula 3 and 4 (OCC) are unacceptable yellow brown colour.
2. Sieve Test
[0091] Formula 1 and 2 (ONP) are acceptable uniform, spherical
granules and similar particle size distribution to standard sodium
bentonite. Formula 3 and 4 (OCC) are unacceptable due to the
irregular large chunks and high level on non-spherical
granules.
3. Clump Strength and Weight
[0092] All 4 Formulas clumped well. Formula 2 performed the best
for clump weight compared to the target of 30 g.
4. Moisture
[0093] All samples had a moisture content of <12.0%,
5. Bulk Density
[0094] Formula 2 had the lowest bulk density result.
6 Airborne Dust
[0095] All Formulas proved to be dust free do to the compact nature
of the particle compared to standard sodium bentonite.
7 Odour Control
[0096] Formula 1 and 2 performed better for odour control.
Example 2
Pelletization Testing
[0097] Pelletization testing was conducted on postconsumer paper
and bentonite. The objective was to produce 100 pounds of durable,
low density, clumping, minus 4.times. plus 18 mesh pellets, as
dried to 8 to 14 per cent moisture content.
[0098] Approximately 58 pounds of postconsumer paper and 192 pounds
of AQUAGEL GOLD SEAL.RTM. sodium bentonite were available for
testing. Materials were blended for testing utilizing a 2.3 &f
mixing capacity concrete mixer.
Raw Material Data
[0099] The postconsumer paper and bentonite raw materials were
analyzed, as received and as tested, for moisture content, bulk
density (table 2.1), and particle size distribution (table
2.2).
TABLE-US-00006 TABLE 2.1 Raw Material Properties Bulk Density Raw
Material % Moisture (aerated) (compacted) ID Content lb/ft.sup.3
kg/l lb/ft.sup.3 kg/l sodium bentonite 13.1% 46.5 0.745 62.3 0.998
40:60 paper to bentonite 9.7% 4.1 0.066 5.4 0.087
TABLE-US-00007 TABLE 2.2 Raw Material Particle Size Distribution
Sieve Sodium Bentonite Mesh mm Retained Cumulative 10 2.000 0.0%
0.0% 45 0.354 0.3% 0.3% 80 0.177 2.8% 3.1% 120 0.125 5.5% 8.6% 200
0.074 18.1% 26.6% 325 0.044 40.3% 66.9% Pan 0.000 33.1% 100.0%
96.9% minus 80 mesh
Test Results
[0100] Representative green pellets were ambient air dried and
analyzed for moisture content, bulk density, attrition loss, (see
table 2.4), and particle size distribution (see table 2.5). A
Mettler Toledo HR83-P Moisture Analyzer, set at 120.degree. C.,
standard (constant temperature) drying program and switch-off
criterion 5 (i.e. 1 mg per 140 seconds), was utilized. Bulk density
analysis was conducted on the pellets as discharged. Attrition
analysis measured per cent losses from minus 7.times. plus 10 mesh
pellets after 5 minutes on a 25 mesh screen in a Ro-Tap.RTM. test
sieve shaker.
TABLE-US-00008 TABLE 2.4 Pellet Properties % Bulk Density Test
Moisture (aerated) (compacted) % Attrition Run Content lb/ft.sup.3
kg/l lb/ft.sup.3 kg/l Loss 3 8.9% 32.4 0.519 39.5 0.633 0.0%
TABLE-US-00009 TABLE 2.5 Pellet Size Distribution Run 3 Sieve 40:60
Paper to Bentonite 8.9% Moisture Content, US Mesh mm Retained
Cumulative 4 4.760 1.1% 1.1% 5 4.000 2.7% 3.8% 7 2.830 17.9% 21.7%
10 2.000 37.1% 58.8% 14 1.410 28.8% 87.6% 18 1.000 9.4% 97.1% Pan
0.000 2.9% 100.0% 96.0% - 6X + 18 mesh
Conclusions
[0101] Durable, low density, clumping, minus 4.times. plus 18 mesh
pellets, dried to 8.9 per cent moisture content (tables 2.4 And
2.5), as judged by measurements of 32.4 lb/ft.sup.3 (0.52 kg/l)
aerated and 39.5 lb/ft.sup.3 (0.63 kg/l) compacted bulk density,
0.0% attrition loss (table 2.4), and successful clumping trials,
were produced from 40:60 postconsumer paper to sodium bentonite
(tables 2.1 and 2.2), with a 12D54L Pin Mixer (see table 2.4).
[0102] Approximately 100 pounds of sample pellets were
produced.
Example 3
Pelletization Testing
[0103] Pelletization testing was conducted on recycled paper and
sodium bentonite. The objectives were to produce 1) 200 pounds of
durable, low density, clumping, minus 8.times. plus 18 mesh
pellets, as dried to 10 to 12 per cent moisture content, made from
a mixture of 40:60 paper to bentonite, having up to 0.5% xanthan
gum content, and 2) 50 pounds of similar pellets, having up to 1.0%
xanthan gum content.
[0104] Approximately 180 pounds of compacted recycled paper
(Climatizer Insulation cellulose fiber), 220 pounds of Aquagel Gold
Seal.RTM. sodium bentonite, and three pounds of food grade xanthan
gum (Neimenggu Fufeng Biotechnologies Co., Ltd., batch no.
M120SA-G19), were available for testing. Materials were blended for
testing utilizing a one cubic yard capacity concrete mixer.
Raw Material Data
[0105] The recycled paper, sodium bentonite and xanthan gum raw
materials were analyzed, as received and as tested, for moisture
content, bulk density (table 3.1), and particle size distribution
(table 3.2).
TABLE-US-00010 TABLE 3.1 Raw Material Properties Bulk Density Raw
Material % Moisture (aerated) (compacted) ID Content lb/ft.sup.3
kg/l lb/ft.sup.3 kg/l recycled paper 6.6% 2.9 0.047 7.5 0.120
sodium bentonite 13.1% 46.5 0.745 62.3 0.998 40:60 paper to
bentonite 9.7% 5.6 0.090 xanthan gum 11.4%
TABLE-US-00011 TABLE 3.2 Raw Material Particle Size Distribution
Sodium Bentonite Sieve as received Mesh mm Retained Cumulative 10
2.000 0.0% 0.0% 45 0.354 0.3% 0.3% 80 0.177 2.8% 3.1% 120 0.125
5.5% 8.6% 200 0.074 18.1% 26.6% 325 0.044 40.3% 66.9% Pan 0.000
33.1% 100.0% 96.9% minus 80 mesh
Test Parameters and Conditions
12D54L Pin Mixer Testing
[0106] A 12D54L Pin Mixer was utilized for testing the recycled
paper to sodium bentonite mixtures, using 0.25% and 0.50% xanthan
gum, in aqueous solution, as liquid binders (table 3.3). The
recycled paper was received in compacted blocks that had to be
broken up prior to mixing with the bentonite.
[0107] A pin mixer is a high speed, conditioning and
micro-pelletizing device that converts powders into small
agglomerates through the action of a high speed rotor shaft and pin
assembly and the addition of liquids such as water, binders, oil or
surfactants. The 12D54L Pin Mixer has a 12'' diameter by 54'' long
mixing chamber, with two available binder nozzle ports. Its maximum
feed throughput is 40 cubic feet per hour.
[0108] The first port was used for liquid binder addition. The
first two numbers of the nozzle tip size represent the angle of the
flat spray. The remaining numbers indicate the flow rate. The 4004
nozzle tip applies 0.4 gallons of water per minute in a 40 degree
spray pattern (at 40 PSI). Test parameters and conditions for the
pin mixer operation are tabulated below (see table 3).
TABLE-US-00012 TABLE 3.3 12D54L Pin Mixer Parameters and Conditions
Feed Liquid Binder Green Pellets Test Rate Nozzle p Rate Pin Mixer
ABD Run ft.sup.3/hr lb/min ID tip PSI gal/min lb/min RPM HP
.degree. C. f P T % MC lb/ft .sup.3 kg/l 1 39.6 3.70 0.25 4004 8
0.191 1.596 1016 13 37 37.4% 42.5 0.680 2 39.6 3.70 0.50 4004 10
0.199 1.664 1016 14 41 32.8% 38.6 0.618 0.25 = 0.25% xanthan gum,
aqueous solution; 0.50 = 0.50% xanthan gum. aqueous solution; p =
pressure; f = rotational frequency; P = power; T = temperature; MC
= moisture content; ABD = aerated bulk density
Test Results
[0109] Representative green pellets were exposed to ambient air to
dry and then analyzed for moisture content, bulk density, clump
strength, (table 3.4), and particle size distribution (table 3.5).
A Mettler Toledo HR83-P Moisture Analyzer, set at 120.degree. C.,
standard (constant temperature) drying program and switch-off
criterion 5 (i.e. 1 mg per 140 seconds), was utilized. Bulk density
analysis was conducted on the pellets as discharged. Clump strength
analysis measured the per cent weight intact portion of each 24
hour aged, syringe-generated clump, after having been dropped from
14 inches into a steel bowl.
TABLE-US-00013 TABLE 3.4 Pellet Properties % Xanthan % Bulk Density
Test Gum Solids Moisture (aerated) (compacted) % Clump Run dry
content Content lb/ft.sup.3 kg/l lb/ft.sup.3 kg/l Strength 1 0.11%
7.6% 44.9 0.719 50.3 0.805 95.8% 2 0.22% 10.0% 42.8 0.686 51.0
0.817 98.2%
TABLE-US-00014 TABLE 3.5 Pellet Size Distribution Run Sieve 0.11%
Xanthan Gum, 0.22% Xanthan Gum, Dry Content; Dry Content; 7.6%
Moisture Content, 10.0% Moisture Content, Mesh mm Retained
Cumulative Retained Cumulative 6 3.360 5.0% 5.0% 1.7% 1.7% 8 2.380
33.8% 38.8% 19.1% 20.8% 10 2.000 21.3% 60.1% 19.0% 39.9% 14 1.410
29.0% 89.1% 36.2% 76.0% 18 1.000 11.1% 100.2% 16.5% 92.6% 40 0.420
4.7% 104.9% 8.9% 101.5% pan 0.000 0.1% 105.0% 0.3% 101.7% 61.4% -
8X + 18 mesh 71.7% - 8X + 18 mesh
Conclusions
[0110] Durable, low density, clumping, minus 8.times. plus 18 mesh
pellets (table 3.5), as judged by measurements of 43 to 45 lb/ft
aerated and 50 to 51 lb/ft.sup.3 compacted bulk densities, and 96
to 98 per cent clump strengths (table 3.4), were produced from
40:60 recycled paper to sodium bentonite, with added xanthan gum
(see tables 3.1 and 3.2), with a 12D54L Pin Mixer (table 3.3).
[0111] The three pounds of xanthan gum was not sufficient to
accommodate an auger feeder; so, the xanthan gum was added in
solution as liquid binder. Due to the resultant increase in
viscosity of the liquid binder upon addition of xanthan gum to the
water, the concentration, sufficient to produce pellets having the
prescribed 0.5% xanthan gum solids dry content, was too thick for
application through a conventional binder tank and spray nozzle.
Instead, 0.25% and 0.50% xanthan gum aqueous solutions were applied
to the raw material in the pin mixer, resulting in pellets having
0.1% xanthan gum solids, dry content, from run 1, and 0.2% from run
2. Approximately 225 pounds pellets from test run 1 and 72 pounds
of pellets from test run 2 were produced.
[0112] It will be appreciated that a person skilled in the art can
make various changes and modifications to the invention to adapt it
to various usages and conditions. As such, these changes and
modifications are within the scope of the present invention. The
scope of the claims should not be limited by the preferred
embodiments set forth in the preferred embodiments, but should be
given the broadest interpretation consistent with the description
as a whole.
* * * * *